Festooned trim clip system and method for attaching festooned clips to a substrate

FIELD OF THE INVENTION

This invention relates to trim and upholstery attachment mechanisms, and more particularly to clips for attaching trim and upholstery to foam and other resilient or flexible substrates.

BACKGROUND OF THE INVENTION

Modern fabric trim covers (upholstery), such as those used in vehicles, often carefully sculpted and shaped to produce a comfortable and aesthetically pleasing effect. As such, the fabric (typically cloth, vinyl or leather with an appropriate backing material) is secured at many locations along its surface to a resilient or flexible backing that defines the cushioned substrate of the upholstered item (for example, a seat bottom, cushion, back or headrest). The substrate is typically constructed from a resilient material. This resilient/flexible material can be synthetic foam (for example polyurethane and/or isocyanate-based foam) or another cushioning material, such as traditional rubberized horsehair, hoghair, and the like. In general, the close-fitting appearance of the upholstery to the substrate requires that the fabric be tacked down to the substrate at any intermediate dips, Vees or trenches in the surface. Otherwise, the fabric will tend to billow or “tent” at these non-planar surface features.

Traditional methods for tacking down trim covers at trenches entail the use of a plastic bead along the inner side of the trim cover. This bead is often located at an inner seam that is a sewn or welded, or otherwise adhered, joint between fabric pieces. Likewise the foam substrate includes an exposed metal wire that may be molded into the substrate along a trench in its surface during its construction. So-called “hog-rings,” consisting of bendable metal ringlets, are then secured to both the plastic bead and the metal wire. These rings are each applied by a tool, such as a hog-ring gun from a supply of wire. As each hog ring is secured, it forms an immovable, permanent joint between the fabric and the substrate. Clearly, this permanent joint is difficult to repair if needed and requires significant skill to create in the first place. In addition, this method of seat cover attachment leads to the development of injuries, such as carpal tunnel syndrome in employees who operate the hog ring tool over an extended period of time. Finally, the use of metal components may be undesirable where the seat includes electrical heating elements due to the metal's predisposition to conduct both heat and electricity.

More recently, trim covers have been secured to resilient substrates using detachable connections that allow repairs to be effected and are often more-easily applied without the used of highly skilled labor. In one example, one side of a hook and loop fastener is attached to a trench in the resilient substrate. The inner surface of the trim cover carries the opposing side of the fastener. This approach is reliable, but expensive, in terms of material wasted and consumed to attain a secure fit. It also requires a rather large-width trench to be formed in the resilient substrate to ensure a sufficient area of engagement between fastener sides.

Another recent approach involves the used of a series of clips that are molded into the trench as a foam substrate is manufactured. A version of this structure, and other prior art attachment mechanisms, are described in U.S. Published Patent Application US/2003/0215601 A1, entitled ATTACHMENT DEVICE, dated Nov. 20, 2003, by Peede, et al. the teachings of which are expressly incorporated herein by reference. A simplified version of such a clip and its use are shown in <figref idrefs="DRAWINGS">FIGS. 1-3</figref> herein. As shown particularly in <figref idrefs="DRAWINGS">FIGS. 1 and 2</figref>, each clip <b>100</b> includes a pair of outwardly facing (with respect to the trim-cover-facing surface of the substrate) legs <b>102</b> that together form a female projection <b>104</b> with a pair of upper hooks or barbs <b>106</b> that face toward each other, thereby defining a top-end funnel, leading into a cavity <b>110</b>. The barbs <b>106</b> define a narrow gap <b>112</b> therebetween. This gap <b>112</b> is smaller in width than the width of the cavity <b>110</b>. The material and relative thickness of the legs <b>102</b> is such that the barbs <b>106</b> can be spread elastically apart so that an appropriately sized cylinder can pass between the legs to be thereafter trapped in the cavity against outward movement by the sprung-back barbs <b>106</b>. In this case, the cylinder is the covered plastic or metal bead <b>120</b> attached to a seam <b>122</b> between two trim cover fabric pieces <b>124</b> and <b>126</b>. This bead assembly is also known as “listing” in the industry. In this example, the bead <b>120</b> is surrounded by a piece of non-woven covering <b>130</b> that retains the bead against the bottom of the seam <b>122</b> using stitching <b>132</b> (or another attachment mechanism). Collectively the diameter of the bead <b>120</b> and covering <b>130</b> define an outer diameter ODB approximately equal to, or slightly less than, the lateral width WB of the cavity <b>110</b>. Thus, in operation, an installer need only press the bead <b>120</b> down between the barbs <b>106</b> (arrow <b>140</b>) so that the angled funnel tops of the barbs cause the legs <b>102</b> to spread, allowing the bead <b>120</b> to pass therebetween. Once the bead <b>120</b> passes fully between the barbs <b>106</b>, then the bead <b>120</b> is mechanically retained beneath the barbs <b>106</b> within the cavity, and the seam <b>122</b> (and facing cover <b>130</b>), extend through the gap <b>112</b> to hold that particular part of the trim cover (<b>124</b> and <b>126</b>) against the clip <b>100</b>.

The clip includes a base <b>150</b> having a relatively thin cross section and an increased surface area adapted to act as an anchor within the (foam) substrate material <b>252</b>. As shown (<figref idrefs="DRAWINGS">FIG. 2</figref>), the base is disposed beneath the surface of a trench <b>254</b>. The base is locked into the matrix of the substrate as a result of the molding process in which foam covers the base and adheres to the base's material. Typically, the clip <b>100</b> is mounted in the bottom of a trench <b>254</b> as shown. In this manner, sufficient setback is provided to allow the seam <b>122</b> to sink into the substrate for a taut fit against its surface.

<figref idrefs="DRAWINGS">FIG. 3</figref> shows an exemplary vehicle seat foam cushion <b>310</b> according the prior art. A plurality of clips <b>100</b> are located along the trench at an appropriate degree of spacing so as to ensure that the bead of the trim cover defines a continuous, unsegmented shape. In the example of a seat bottom or back, approximately 12-30 clips may be needed to define a desired shape. In general, the tighter the curvature of the substrate, the smaller the clip spacing provided. The above-referenced published U.S. patent application contemplates that the spacing between clips can be regulated, in part, by providing fixed-space, flexible connectors between individual clips and molding such clips into the foam substrate with the predetermined spacing defined by the connectors.

The above-prior art clips typically constructed from a resilient material, which allows for the flexure imparted by insertion of the bead into their respective cavities. However, these clips should also adhere firmly to the foam or other resilient substrate material. Hence, the clip material should exhibit properties so that it appropriately adheres to the substrate so that it will not eventually detach under long-term use.

The process of inserting clips into a foam mold cavity, used for example to form seat parts, is typically a manual operation that is time-consuming, labor-intensive and sometimes subject to inaccurate placement. Clips are dispensed from inside loosely packed boxes, and each one must be individually picked, reoriented properly, and inserted into the appropriate location in the mold cavity for subsequent foam application thereover. This process contains inherent inefficiencies that the worker cannot fully overcome. Moreover, loosely packing ganged groups of clips, connected by intermediate connecting segments further complicates handling. It has been found that a loosely packed supply of ganged clips generally assumes a “bird's nest” entanglement that is extremely difficult to unravel.

Accordingly it is desirable to provide a system for dispensing clips that makes their orientation predictable, and handling more efficient. It is further desirable that the system entail minimal or no waste, and potentially allow for the placement of multiple “ganged” clips into the foam mold cavity at one time. The clips of this system should also display good general adhesion to foam so as to minimize subsequent detachment or pullout, while still withstanding normal cyclic loads and other stresses likely to be encountered in assembly and subsequent long-term use.

SUMMARY OF THE INVENTION

This invention overcomes the disadvantages of the prior art by providing a single or multi-ganged clip that can be grouped into a festooned arrangement. That is, a plurality of clips are arranged together into a discrete assembly along a line of extension so that a human or automated handler can retrieve a grouping, separate one-clip-at-a-time from the grouping, and apply the separated clip to a mold cavity or other assembly structure. Each clip can include a base with opposing ends aligned in the direction of extension and transverse to an elongation direction for a connecting segment (if any) between ganged clip members. In an illustrative embodiment, these base ends include opposing male and female connectors. In this embodiment the male connector is a cylinder with an axis that extends transverse to the direction of elongation and the female connector defines a conforming cylindrical inner diameter, which allows it to nest over the male cylinder. A gap opening is provided at the far edge of the female connector to provide clearance for the base that connects the male cylinder to the clip member base end. This gap can be sized to allow a predetermined range of angular rotation of the male connector about its axis within the female connector. Clips can be stored as discrete groupings that are stacked in a container or paid out in a continuous grouping from a spool.

In an alternate embodiment, the male connector can be side braces that extend from the clip member's base end and thereby define a slot between the base end and the male cylinder. The female connector can be sized in lateral width and thickness to ride within the slot as the adjoining clips are angularly rotated with respect to each other. This arrangement affords a greater range or bending that can be useful in continuous feed implementations. The bases of clip members can be provided with holes that are engaged by a tractor pin-feed mechanism, or another drive formation can be provided to the clips. Any of the clips contemplated herein can be assembled into unitary or detachable multi-ganged arrangements of clip members separated by (narrowed) connecting segments. In a dual ganged configuration, male and female connectors on opposing clip members of a given clip can be located on opposite base end sides, thereby allowing clips to be attached to each other ambidextrously.

The above-described clips, and other types clips that are adapted to be mounted within foam, can be constructed from a material that reacts chemically with the foam in a liquid state. An illustrative material is polycarbonate, and it is expressly contemplated that other similar materials with needed heat-resistance, durability and (optionally) surface reactivity to liquid foam can be employed to construct clips and/or clip member bases in accordance with this invention.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention description below refers to the accompanying drawings, of which:

<figref idrefs="DRAWINGS">FIG. 1</figref>, already described, is an exploded fragmentary perspective view of a trim cover bead and clip according to the prior art;

<figref idrefs="DRAWINGS">FIG. 2</figref> is, already described, is a fragmentary side cross section of the clip and trim cover bead of <figref idrefs="DRAWINGS">FIG. 1</figref> mounted in an exemplary substrate trench;

<figref idrefs="DRAWINGS">FIG. 3</figref>, already described, is a fragmentary perspective view of an exemplary substrate (a seat bottom) having a surrounding inboard trench with a plurality of clips molded thereinto and receiving a piece of a trim cover bead;

<figref idrefs="DRAWINGS">FIG. 4</figref> is a perspective view of an exemplary festooned grouping of a plurality of dual-ganged clips according to an illustrative embodiment of this invention;

<figref idrefs="DRAWINGS">FIG. 5</figref> is a perspective view of a single dual-ganged clip from the festooned grouping of <figref idrefs="DRAWINGS">FIG. 4</figref>;

<figref idrefs="DRAWINGS">FIG. 6</figref> is a side view of the clip of <figref idrefs="DRAWINGS">FIG. 5</figref>;

<figref idrefs="DRAWINGS">FIG. 7</figref> is a partially cut-away perspective view of a storage and dispensing box for use with predetermined-size festooned groupings of dual-ganged clips according to an embodiment of the invention;

<figref idrefs="DRAWINGS">FIG. 8</figref> is a perspective view of a storage and dispensing spool for use with continuous-run, festooned grouping of dual-ganged clips according to an embodiment of the invention;

<figref idrefs="DRAWINGS">FIG. 9</figref> is a partial side view of two layers of spooled clips in accordance with the embodiment of <figref idrefs="DRAWINGS">FIG. 8</figref>;

<figref idrefs="DRAWINGS">FIG. 10</figref> is a perspective view of an exemplary festooned grouping of a plurality of dual-ganged clips, adapted for greater angular deflection between clips, according to an alternate embodiment of this invention;

<figref idrefs="DRAWINGS">FIG. 11</figref> is a side view of the festooned grouping of clips according to <figref idrefs="DRAWINGS">FIG. 10</figref> illustrating an increased range of possible angular deflection;

<figref idrefs="DRAWINGS">FIG. 12</figref> is a perspective view of an exemplary festooned grouping of a plurality of dual-ganged clips, employing a pair of flexible strips to which ganged clips are removable attached, according to an alternate embodiment of this invention;

<figref idrefs="DRAWINGS">FIG. 13</figref> is a partial perspective view detailing a typical application of dual-ganged clips to a mold cavity according to an embodiment of this invention;

<figref idrefs="DRAWINGS">FIG. 14</figref> is a perspective view of a triple-ganged clip adapted to be assembled into a festooned grouping of variable size according to an alternate embodiment of this invention;

<figref idrefs="DRAWINGS">FIG. 15</figref> is a perspective view of a festooned grouping of single clips in accordance with an alternate embodiment of this invention;

<figref idrefs="DRAWINGS">FIG. 16</figref> is a somewhat schematic exposed side view of a mold assembly used to form multi-ganged festooned clips in accordance with an embodiment of this invention, shown in a closed orientation;

<figref idrefs="DRAWINGS">FIG. 17</figref> is a somewhat schematic side view of the mold assembly of <figref idrefs="DRAWINGS">FIG. 16</figref> shown opened so as to allow removal of an exemplary dual-ganged molded clip; and

<figref idrefs="DRAWINGS">FIG. 18</figref> is a partially exposed perspective view of an exemplary clip constructed from a material in accordance with an embodiment of this invention that exhibits chemical adhesion in contact with commercially available foam substances.

DETAILED DESCRIPTION

<figref idrefs="DRAWINGS">FIG. 4</figref> shows a festooned grouping <b>400</b> of dual-ganged clips <b>410</b> according to an embodiment of this invention. With reference also to <figref idrefs="DRAWINGS">FIGS. 5 and 6</figref>, the clips <b>410</b> comprise a pair of opposed clip members <b>412</b> (also sometimes referred to herein as “clips”), joined by a central shaft segment <b>414</b>. Each discrete clip <b>410</b> in the festooned grouping is a unitary structure, with the clip members <b>412</b> and adjoining intermediate segment <b>414</b> being molded together as a single unit. As will be described below alternate forming techniques, such as extrusion are also contemplated.

The clips <b>410</b> of this invention can be constructed from a variety of materials, which will also be described in further detail below. In general, the material should be durable, capable of withstanding reasonable levels of heat and pressure and flexible so as to provide a good spring material. To this end, it is noted that each clip member <b>412</b> includes a pair of upright leg assemblies <b>416</b> extending from a generally planar, central base <b>520</b>, which define therebetween a gap <b>418</b>. This gap <b>418</b> allows insertion of the bead of a listing member (or other structure-to-be-secured) thereinto. In general, the legs are adapted to move elastically away from each other as a bead is passed through the gap.

Referring particularly to <figref idrefs="DRAWINGS">FIGS. 5 and 6</figref>, the leg assemblies <b>416</b> each include a respective inwardly slanted hook or barb <b>420</b> that together help to guide and/or funnel the listing into the gap <b>418</b>. In addition, the barbs <b>420</b> each define an inner shoulder <b>610</b> (<figref idrefs="DRAWINGS">FIG. 6</figref>) that restricts outward movement of the listing, or other structural member, once it is forcibly inserted though the gap <b>418</b>. The leg assemblies <b>416</b> are sized in thickness so that they exhibit a predetermined level of spring elasticity with respect to the central clip base <b>520</b>. The size and shape of the clip base is highly variable. While not shown, the central clip base <b>520</b> can include a reinforcing rib, or other reinforcing structure, which extends below the flat upper portion <b>632</b> to help prevent flexure and/or breakage of the base <b>520</b> as the leg assemblies <b>416</b> are spread apart in certain embodiments. Any additional base reinforcement, as well as the general perimeter shape of the base <b>520</b> (shown here as a basic rectangle) are adapted to provide needed surface area for adhesion to the foam substrate as will be described further below. The particular structure of the base and leg assemblies are both highly variable and a variety of reinforcing ribs, flanges and other structures can be appended to each clip member as appropriate. The degree of reinforcement depends, in part, on the strength and durability of the materials employed to form the clip and the environment to which the clip is exposed during assembly and subsequent use.

Notably, extending from opposite ends of the base <b>520</b> (in a direction transverse to the elongation of the segment <b>414</b>) is provided a pair of attachment members or “connectors” <b>510</b> and <b>512</b>. In this embodiment, one attachment member <b>510</b> is an elongated cylindrical male connector and the opposing attachment member <b>512</b> is an open, semi-cylindrical female connector. The diameter DM of the male connector conforms relatively closely to the inner diameter DF of the female connector. In fact, DM can be slightly larger than DF in order to define a friction fit to maintain a given angular orientation between joined connectors <b>510</b>, <b>512</b>.

As shown particularly in <figref idrefs="DRAWINGS">FIG. 4</figref>, on adjacent clip members <b>412</b>, each of the male connectors <b>510</b> is nested within a respective female connector <b>512</b> to define the depicted, festooned grouping of clips <b>400</b>. The open gap <b>530</b> in each female connector includes the spacing distance GS (see <figref idrefs="DRAWINGS">FIG. 6</figref>) that is generally greater than the distance of the male connector base <b>640</b> (see <figref idrefs="DRAWINGS">FIG. 6</figref>), which extends between the central clip base <b>520</b> and the body of the mail connector <b>510</b>. In this embodiment, the connector base <b>640</b> is a curved segment that positions the male connector slightly below the top plane of the central base <b>520</b>. As will be described below, the female connector gap GS allows for limited rotational movement of male connectors when nested within female connectors. For the purposes of this embodiment, the male connector diameter DM is approximately three millimeters. The female connector inner diameter DF is approximately three millimeters with a slight reduction in relative size to provide the desired friction fit. The gap distance GS is approximately two millimeters, while the thickness TF of the female connector <b>512</b> is approximately one millimeter. The width WC (<figref idrefs="DRAWINGS">FIG. 5</figref>) of the male and female connectors is approximately eight millimeters. It is noted that these measurements are all exemplary and can be varied as appropriate depending upon the materials used and the application for the clip. In general, in the depicted applications, measurements such as width WC and diameter DM/DF can vary by several millimeters in alternate embodiments. The dimensions of the leg assemblies <b>416</b> are, likewise, highly variable. The leg assembly dimensions can be based upon the size and shape of the listing being engaged and other factors, such as the thickness of the foam substrate. The thickness TB of the base <b>520</b> is in a range of between approximately 1.5 to 2 millimeters in an exemplary embodiment. The thickness <b>640</b> of the male connector base is approximately one millimeter. This is sufficiently smaller than the gap distance DF for a female connector to allow the above-described rotational movement between clips, within a pre-determined range of arcuate, rotational movement.

Referring further to grouping <b>400</b> shown in <figref idrefs="DRAWINGS">FIG. 4</figref>, it is noted that each dual-ganged clip <b>410</b> is provided with alternating female and male connectors <b>512</b>, <b>510</b> (respectively) on a given side of the clip. In other words, as depicted, the left hand clip member includes a male connector <b>510</b>, while the right hand clip member includes a female connector <b>512</b>. In the exemplary dual-ganged arrangement, this ensures that each clip is “ambidextrous” with respect to adjacent clips. In other words, each clip can be attached to adjacent clips in either of two orientations. This, of course, assumes that all clips are assembled with leg assemblies <b>416</b> facing the same (upward) direction. In alternate embodiments, male connectors can both be disposed on the same clip side and female connectors can both be placed on the opposite clip side. Such clips would not exhibit the above-described ambidextrous capability.

In the depicted embodiment, a central enlarged tab <b>560</b> is provided along the connecting segment <b>414</b>. This tab is optional, and is, in part, a byproduct of the molding processors used to form the clip <b>410</b>. However, this tab <b>560</b>, as well as other structures on the clip <b>410</b>, can be used to provide an identifying mark (such as the depicted “X”), which may indicate information manufacturing date, lot number and/or other desirable data. The enlarged tab <b>560</b> may also assist a worker in grasping the given clip for assembly into a foam structure. Similarly, the clip may provide a useful grasping point for removal of the clip from a clip-formation mold using manual or automated possesses.

In this embodiment, the base <b>520</b> of each clip also includes opposing throughout holes <b>570</b>. These holes are optional, but can be sized and arranged so as to allow the clip segment to be driven by an appropriately sized and shaped tractor-pin-feed drive unit. Such a unit is particularly desirable where clips are fed in a continuous line, as will be described further below.

The number of clips grouped together, in accordance with the arrangement of <figref idrefs="DRAWINGS">FIG. 4</figref>, can be highly variable. In practice, an unlimited number of clips can be grouped together, thereby extending the group continuously along a line elongation (dashed line <b>450</b> in <figref idrefs="DRAWINGS">FIG. 4</figref>) define a festooned grouping of clips that suits a given end user's needs. One possible arrangement of grouped clips of clips is shown in <figref idrefs="DRAWINGS">FIG. 7</figref>. As depicted, a box or crate <b>710</b> has been provided with four separated compartments <b>720</b> and an open top. Within each compartment <b>720</b> is a stack of festooned groupings of clips <b>730</b>. In this embodiment, each clip grouping <b>730</b> includes five interconnected, dual-ganged clips <b>410</b>. The actual number of connected clips in a stacked grouping is highly variable in alternate embodiments. The exemplary group of five festooned clips generally provides for an easily manipulated size and shape for the average worker. By providing an integral, assembled group of clips, it stacks easily with respect to other groups without the risk of entanglement between groups. This is, in part, because each line of assembled clip members essentially establishes a continuous, flat strip that lies squarely on the tops of the leg assemblies of the underlying group. Hence, each grouping is supported by the combined expanse of leg assemblies in the underlying group. This prevents birds-nest-style entanglement that would result from a loosely packed supply of individual dual-ganged clips. The walls of each compartment are sized to restrict lateral (aligned with the connecting segments) and front-to-rear movement of each grouping. The flat bases of the clips remain squarely positioned over the leg assemblies of the underlying group in the stack.

In the exemplary storage embodiment of <figref idrefs="DRAWINGS">FIG. 7</figref>, there are twenty-three layers of clip groups divided into four compartments. A worker can easily lift each group out as a single unit as needed. With proper sizing, the box <b>710</b> can be arranged to define a cube with an approximate dimension of twelve inches by twelve inches by twelve inches in an exemplary embodiment. Boxes having other sizes, shapes and compartment arrangements are expressly contemplated in alternate embodiments.

In use, a worker or mechanical device removes a grouping of clips <b>730</b> from the top of a stack in one of the compartments <b>720</b>. As needed each individual clip is then detached from the grouping by either (a) applying front-to rear tension to pull the clip away from the adjacent clip in the grouping pulling them apart (thereby spreading the female connector gap <b>530</b> and overcoming the spring force of each female connector, or (b) are sliding the clip laterally (in the direction of extension of the connecting segment (<b>414</b>)) relative to an adjacent clip in the grouping. Lateral sliding requires less force in most instances, but may require more dexterity than simply pulling clips apart. In either case the material of the clip member and the dimensions of male and female connectors are adapted to allow application of reasonable force without causing the clips to break. Once separated, clips can be assembled into a mold cavity by hand, or automated action, as described generally below.

Because the novel system for allowing grouping of clips of this embodiment provides for an unlimited length and a moderate degree of angular rotation between assembled groupings of clips, the system lends itself to the provision of a long, continuous length of clips on a reel or spool. An exemplary spooled arrangement of clips is shown in <figref idrefs="DRAWINGS">FIG. 8</figref>. The spool <b>810</b> includes and open central core <b>820</b> that supports a continuous length grouping <b>830</b> of clip s <b>410</b> in accordance with an embodiment of this invention. Because the bases of the clips form a continuous surface, they rest fully supported over the leg assemblies of underlying clips without falling through the underlying clips. To help prevent entanglement, this embodiment, the spool <b>810</b> includes two closely fitting side flanges <b>840</b> that restrict axial movement of clips so that each layer of grouped clips remain squarely located over the leg assemblies of the underlying clip layer.

Also referring briefly to <figref idrefs="DRAWINGS">FIG. 9</figref>, the relationship between layers of stacked clips on a spool is shown in further detail. As depicted, each clip <b>410</b> is allowed to angularly deflect about a respective rotational axis <b>810</b> relative to an adjacent clip. The angular deflection (as defined by the relative orientation of the plane of each clip's base with respect to that of an adjacent clip's) of each clip with respect to an adjacent clip, in a spool arrangement, is determined by where the line of connected clips are with respect to the core <b>820</b>. The minimum diameter of the spool core is generally restricted by the maximum bend angle between adjacent, connected clips. The bend angle can be varied, in part, by varying the diameter of the male and female connections <b>510</b> and <b>512</b> and increasing the width GS of the female connector gap spacing <b>530</b>. However, angular deflection is essentially limited to a predetermined range that corresponds to a minimum core diameter in this embodiment.

An alternate embodiment for a clip <b>1010</b> is shown in <figref idrefs="DRAWINGS">FIG. 10</figref>. This clip <b>1010</b> also consists of a dual-ganged configuration with clip members <b>1012</b> on each of opposing ends of a narrowed, central joining segment <b>1014</b>. This clip <b>1010</b> includes similarly constructed leg assemblies <b>1016</b> to those described above with respect to the clip <b>410</b> for engaging an appropriately dimensioned listing bead. The female connector <b>1022</b> of each clip is sized and arranged similarly to the female connector <b>512</b> described above. However, the male connector <b>1030</b> for each clip member <b>1012</b> is arranged on a pair of forwardly extending side braces <b>1032</b> that define an open central well or slot <b>1034</b> between the central base <b>1040</b> of the clip member <b>1012</b> and the cylindrical body of the male connector <b>1030</b>. This well is sized and arranged so that, when a female connector <b>1022</b> is attached to a male connector <b>1030</b>, the female connector rides within the slot <b>1034</b>. In other words, the slot <b>1034</b> has a width in each of two orthogonal directions that is generally greater than the corresponding thickness and width of the female connector.

As shown further in <figref idrefs="DRAWINGS">FIG. 11</figref>, the relative arrangement of the male connector <b>1030</b> and female connector <b>1035</b> allows each clip connected to move rotationally within a substantial range of angular deflection (shown in phantom) to allow the line of connected clips to be wrapped around a small-diameter core. In this example, the connected clips may actually bend to relative angles (defined by the plane on each clip's central base <b>1040</b>) in excess of 90 degrees (see double-curved arrow <b>1060</b>). This added range of inter-clip angular deflection may also be beneficial where clips are likely to be fed along a continuous line that contains various turns and bends. Also, this arrangement may be beneficial where lines of clips are subjected to significant bending during manual handling. Over-bending of clips with a low-degree of tolerable angular deflection may otherwise cause their ends to break.

Another technique for providing a festooned grouping of clips is shown in <figref idrefs="DRAWINGS">FIG. 12</figref>. In this embodiment, the exemplary clips <b>1210</b> include two clip members <b>1212</b> joined by a unitary central segment <b>1214</b>. In this embodiment each clip member also includes opposing ends <b>1220</b> (in the direction of feeding/grouping-dashed lines <b>1218</b>) that are free of any clip-to-clip connectors, or other like structures. A continuous flexible strip or tape <b>1230</b> underlies each clip member <b>1212</b>. The clip members <b>1212</b> are placed at a predetermined spacing SC along each strip <b>1230</b>. Each strip <b>1230</b> can carry a continuous coating of adhesive, or a concentrated adhesive spot <b>1240</b> that specifically underlies the location of each attached clip member <b>1212</b>. The adhesive can be any desirable industrial adhesive capable of removably securing the clip to the strip. Likewise, the strip <b>1230</b> can be constructed from paper, polymer sheet or any other synthetic/natural sheet material with the ability to flex and bend as shown. As clips <b>1214</b> are needed by a worker or automated device, they are torn from the strip, whereby the adhesive contact between the strip and each overlying clip member is broken. In alternate embodiments, one or more strips <b>1230</b> can be adhered to each clip between clip members, within the center region of the grouping, along, for example, the central segment <b>1214</b>. In still further alternate embodiments, a pair of confronting strips may sandwich the segments <b>1214</b>. In such an arrangement, clips can be removed by separating the two strips and withdrawing the clip therefrom in the manner of peeling a banana skin to withdraw the fruit.

While a tape or strip-base holding system has advantages in that it is highly flexible, it should be noted that this arrangement also provides an extra component that may add waste, and may become fouled in certain machinery. Thus, this embodiment may not be desirable in some instances.

With reference now to <figref idrefs="DRAWINGS">FIG. 13</figref>, a typical procedure for employing clips <b>410</b>, once they are removed from a festooned group is shown. In this embodiment, a portion of an exemplary foam cushion mold cavity <b>1310</b> is depicted. This mold cavity includes rails <b>1320</b> upon which ganged clips <b>410</b> are mounted. In particular, each clip member's leg assemblies <b>416</b> are passed over narrowed webs <b>1330</b> formed within breaks <b>1332</b> in the rails <b>1320</b>. As liquid foam is introduced to the mold cavity, the rails <b>1320</b> define trenches within the foam, such as those described above with reference to <figref idrefs="DRAWINGS">FIG. 3</figref>. The clips subsequently reside in the trenches with gaps between their legs exposed for insertion of listing. The rail webs <b>1330</b> provide accurate reference point for positioning clips during the molding process. They also prevent undesired movement of the clips while the foam is applied and cures.

As shown in <figref idrefs="DRAWINGS">FIG. 13</figref>, a worker's hand <b>1350</b> grasps a central segment <b>414</b> of the subject clip <b>410</b> and inserts it so that its leg assemblies <b>416</b> surround the web. The completed insertion is shown in the foreground of the illustration. When liquid foam is applied, it will surround and engage the clip members <b>412</b> and the central segment <b>414</b> so as to retain them with respect to the foam. As noted above, the particular materials employed to construct the clip <b>410</b> influence the effectiveness of the adhesion between the solidified foam and the embedded clip. In an alternate embodiment, it is contemplated that the process for insertion of single or ganged clips can be automated. One such automation technique is described with reference to rail clips. This process employs an end-effector that grasps and deposits clips onto a mold cavity. This process is described with reference to U.S. patent application Ser. No. 11/615,954 entitled CLIP FOR JOINING TUBULAR MEMBERS TO SUBSTRATES by Andrew W. Santin et al., the teachings of which are expressly incorporated herein by reference. It should be clear that a variety of robotic and/or electromechanically techniques can be employed to affect automation of clip placements. Such automation can employ a continuous feed of clips from for example, a spool as shown in <figref idrefs="DRAWINGS">FIG. 8</figref>.

The above-described embodiments show and define a dual-ganged clip. A dual-ganged clip has certain advantages in particular applications. It allows for ambidextrous interconnection, is not so elongated as to flop or flex excessively and is relatively easy to manipulate. However, it is expressly contemplated that the number of ganged clip members on a given groupable clip structure can be greater or less than the two joined clip members <b>412</b> shown and described above.

Thus, <figref idrefs="DRAWINGS">FIG. 14</figref> details a triple-ganged clip <b>1410</b>. The three separated clip members <b>1412</b>, <b>1414</b> and <b>1416</b> on this unitary clip <b>1410</b> are joined by intervening segments <b>1418</b> and <b>1420</b>. Each clip member <b>1412</b>, <b>1414</b> and <b>1416</b> includes an associated male connector <b>1430</b> and female connector <b>1432</b>, which are generally similar in size and shape to the male connector <b>510</b> and female connector <b>512</b> described above. A three-ganged implementation lacks the ambidextrous capability of the above-described embodiments. However, such a three (or-more) ganged clip arrangement can be stored in a similarly festooned grouping (box or spool), and handled in a similar manner to those described above.

In another embodiment, a single clip member <b>1510</b> is shown in <figref idrefs="DRAWINGS">FIG. 15</figref> as part of a festooned grouping of single clips. This grouping includes male connectors <b>1520</b> engaging adjacent female connectors <b>1522</b>. These connectors define geometry similar to, or the same as that attached to the above-described clip members <b>412</b>. Single ganged and multi-ganged from multi-ganged clips can all be provided on an appropriately sized spool to be dispensed as needed to a worker or automated clip-placement device.

By employing appropriate manufacturing techniques, clips can be formed using extrusion, injection molding or other commercially available forming procedures. In a case of an extrusion, clips should be formed so that their features are relatively similar in an elongated direction. As the reader may surmise, such extrusion manufacturing procedures are readily employed for forming a single clip, such as that shown in <figref idrefs="DRAWINGS">FIG. 15</figref>. However, where the clip involves multiple-ganged clip members separated by narrow segments, extrusion may not provide the most effective forming technique. For such multi-ganged clips, an exemplary injection molding technique is, thus, detailed if <figref idrefs="DRAWINGS">FIGS. 16 and 17</figref>. As shown in <figref idrefs="DRAWINGS">FIG. 16</figref>, the liquefied material that, when solidified, forms the finished clip is injected into a mold cavity, which defines the clip outline (in phantom lines). This exemplary mold <b>1600</b> is defined by four engagable and disengageable pieces. A shown, the mold <b>1600</b> consists of a top section <b>1610</b> that generally defines the middle segment <b>414</b>, a bottom section <b>1620</b>, which forms the base of the clip, and two side sections <b>1630</b> that define the cavities for the corresponding clip member base and legs.

Once the liquid clip material has solidified within the mold <b>1600</b>, the mold sections <b>1610</b>, <b>1620</b> and <b>1630</b> are withdrawn as shown in <figref idrefs="DRAWINGS">FIG. 16</figref> according to a defined order. In particular, the bottom section <b>1610</b> can be withdrawn first (arrow <b>1730</b>). This is followed by withdrawal of the side sections <b>1630</b> (arrow <b>1720</b>), and finally by withdrawal of the top section <b>1620</b> (arrow <b>1710</b>). A completed clip <b>410</b> is, thus, reviled and ready for assembly into a festooned grouping. A variety of alternate mold geometries can be employed in alternate embodiments.

Note that it is contemplated that available part-forming techniques can be employed to mold (or otherwise form) a plurality of clips together in a festooned grouping that with the constituent clips already removably connected together. In other words an entire festooned grouping is molded together. In such a procedure, a thin liquid-impermeable boundary is established between male and female connectors as they are molded. When the side pieces of such a mold are removed, the previously separated male and female connectors are brought into contact with each other. At this time they are separate components and capable of rotating with respect to each other.

As described above, it is desirable to construct a clip in accordance with this invention using materials that exhibit durability, heat-resistance, and the ability to chemically bond with ordinary foams as used in commercially available seat cushions. Durability and heat resistance are particularly desirable as it is common for the temperature of foam to rise substantially during the molding process, which may melt and/or thermally deform clips constructed from certain materials. Clips may also be prone to breakage and deformation due to the application of roll crushers (which may be heated) to the foam cushion to aid in its formation. These rollers may undesirable crush clips that are constructed from weaker/less-durable materials.

With reference to <figref idrefs="DRAWINGS">FIG. 18</figref>, surface bonding of the clip member <b>412</b> relative to the overlying foam <b>1810</b> is illustrated. In a typical implementation, the foam has been removed from the region surrounding the clip to show a surface that has been etched due to the action of chemical bonding with the foam while it is in liquid form, as shown by the depicted roughened surface on the clip member <b>412</b> and adjoining segment <b>414</b>. The surface of a clip member can be relatively smooth, or can be provided with a variety of different types of surface textures and/or structures that increase bondable surface area.

It is contemplated that foams can typically comprise polyurethane compositions that are based upon methylene-diphenyl-diisocyanate (MDI) and toluene-diisocyanate (TDI), respectively representing the commercial application of so-called cold cure and hot cure foam technologies. Each of these types of foams have been shown to react chemically with certain types of hard polymers (plastics) during curing from a liquid to a solid state. A variety of materials possess these characteristics, and can be used to form clips. Some examples include, but are not limited to, nylon, polybutylene terephthalate (PBT), and polycarbonate (PC) compounds. In particular, polycarbonate can be transparent, allowing defects to be detected, has excellent molding characteristics, allowing small features to be defined in parts and has superior heat-resistance, which better survives the exothermic effects of certain foams (in which temperatures can exceed 130 C), without melting or deforming under the pressure of a roll crusher. Polycarbonate is also quite durable and long-lived under cyclic loading.

In summary, the above-described single or ganged clips, which can be provided as a festooned grouping, afford a human or automated handler with a superior system for efficiently manipulating and placing clips in a mold or other mounting assembly. By selecting appropriate materials, these clips (and other clip types) are effectively and permanently adhered to foam by chemical adhesion. They resist heat and pressure, and exhibit high long-term durability.

The foregoing has been a detailed description of illustrative embodiments of the invention. Various modifications and additions can be made without departing from the spirit and scope if this invention. Each of the various embodiments described above may be combined with other described embodiments in order to provide multiple features. Furthermore, while the foregoing describes a number of separate embodiments of the apparatus and method of the present invention, what has been described herein is merely illustrative of the application of the principles of the present invention. For example, while clips can be constructed from a material that readily bonds to liquid foam, in alternate embodiments, all or part of the clip material can be relatively inert to foam and bonded by alternate mechanisms, such as adhesives or mechanical anchoring. In addition, it is expressly contemplated that any of the storage techniques, festooning arrangements and connector structures described above can be applied to clips of any number of ganged clip members (e.g. single, dual-ganged, triple ganged, etc.). Also, while clip members are joined by unitary segments of predetermined length according to illustrative embodiments, it is expressly contemplated that the segment connectors between clip members in a multi-ganged clip arrangement can be completely or partially removable from the clip members in the arrangement. As such, the segments can be variably sized to allow adjustment of the spacing between ganged clip members. Likewise, the clip members can be provide as a multi-piece unit with the clip legs (being possibly more durable) being a separate material with respect to the base (being possibly more reactive to foam). Alternatively, a unitary clip with a multiplicity of co-molded or co-extruded materials can be formed. Furthermore, while male and female connectors in the depicted embodiments are generally cylindrical so as to facilitate angular rotation between adjoining clips, in alternate embodiments (where angular rotation is not desired) the connectors can each define a conforming, nesting, non-circular cross section (such as an oval, polygon, etc.). In such an embodiment, clips would be urged to maintain a predetermined angular orientation with respect to each other. This may be desirable for storage implementations, such as the box of <figref idrefs="DRAWINGS">FIG. 7</figref>. Moreover, while a particular male and female connector are provided to each clip member in the illustrative embodiments, the general term “connector” should be taken broadly to include genderless connectors that freely interconnect with each other regardless of orientation. Accordingly, this description is meant to be taken only by way of example, and not to otherwise limit the scope of this invention.